Mineral fibers decomposable in a physiological medium

ABSTRACT

The present invention relates to mineral fiber compositions useful for forming fibers which are readily degraded in a physiological medium such as that found within the human body. Advantageous compositions formed according to the present invention comprise the following components in the proportions by weight set forth below: 
     
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     SiO 2   37 to 58 wt. %;                                                
Al 2  O 3                                                           
           4 to 14 wt. %;                                                 
CaO        7 to 40 wt. %;                                                 
MgO        4 to 16 wt. %;                                                 
P 2  O 5                                                            
           1 to 10 wt. %;                                                 
Fe 2  O 3                                                           
           up to about to 15 wt. %:                                       
______________________________________                                    
 
     wherein the amount of CaO+MgO+Fe 2  O 3  is greater than 25% and the total amount of Na 2  O+K 2  O is less than 7%. The total iron contained within the composition is expressed in the form of ferric oxide (Fe 2  O 3 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

Continuation of Ser. No. 708,661, May 31, 1991, abandoned .[., which isa continuation-in-part of Ser. No. 565,282, Aug. 9, 1990, U.S. Pat. No.5,108,957.]..

FIELD OF THE INVENTION

The present invention relates to mineral fibers which, by virtue oftheir composition, are readily decomposable upon contact with aphysiological medium.

BACKGROUND OF THE INVENTION

Buildings are frequently insulated with respect to heat and sound byproducts incorporating mineral fibers, such as rock or slag fibers. Theparticular arrangement of the premises to be insulated often requiresthe personnel responsible for fitting these products to cut and/or shapethem at the job site, this operation, however, typically causes breakageof the fibers and the possible dispersion of some of these fibers and/orfiber fragments into the atmosphere.

In a like manner mineral fibers are also used in industry to produce,e.g., geometrically shaped panels and tubular products for variousapplications. In addition such fibers are also commonly used in industryto form, e.g., mats sewn over cardboard or metal grills or netting toform pads or alternately to form such pads by filling in bulk form. Inmany of these applications the finished product must be cut and/orshaped prior to its final installation.

It follows, therefore that at times there is a danger of accidentalinhalation of fibers or fiber fragments by those who come into contactwith them. Although the inhalation of these fibers and/or fragments hasnot been demonstrated to be harmful, the need is felt to reassure thoseworking with these products by offering them a demonstrably safeproduct.

SUMMARY OF THE INVENTION

An object of the present invention is to provide mineral fibers having acomposition which decomposes rapidly upon contact with a physiologicalmedium. By a "physiological medium", applicants make a medium such asthat typically found within a human body.

A further object of the present invention is to provide compositionwhich may be formed into decomposable fibers of the type described aboveby the use of so-called "outer" centrifugation techniques.

Outer centrifugation techniques, which are well known in the art, aretypically used to form fibers from glasses obtained by melting rawmaterials such as blast furnace slag or basalts. Some of thesetechniques, also referred to as free centrifuging techniques, involvepouring a thin stream of molten glass onto the peripheral strip of acentrifuging wheel rotating at high speed about a shaft perpendicular tothe direction of the thin glass stream. Under the effect of centrifugalforce, some of the glass is converted into fibers, with the remainder ofthe glass being conveyed to a second wheel where the same procedure isrepeated. In this manner, therefore, three or four wheels may beinterposed along the path of the molten glass. Techniques such as thosedescribed above are particularly useful in forming the mineral fibers ofthe present invention.

The objects of the present invention are achieved by modifying knownglass compositions typically used in the free centrifuging techniquesdescribed above. Based upon compositions of this type, essentiallycomprising silica, alumina and alkaline earth oxides, it has beendiscovered that the addition of phosphorus pentoxide results in theformation of mineral fibers which decompose rapidly in a physiologicalmedium.

It has further been found that mineral fibers formed from thecompositions of the present invention do not suffer any substantialdiminution of their properties in comparison to those of prior artproducts, i.e., those which are only slightly or not at all decomposablein a physiological medium. Thus, the compositions of the invention canbe readily converted into fibers using conventional centrifuging wheels.

The mineral fibers formed according to the present invention areprepared from compositions comprising the following components (inweight percent):

    ______________________________________                                               SiO.sub.2    37 to 58%                                                        Al.sub.2 O.sub.3                                                                            4 to 14%                                                        CaO           7 to 40%                                                        MgO           4 to 16%                                                        P.sub.2 O.sub.5                                                                             1 to 10%                                                        Fe.sub.2 O.sub.3                                                                           up to 15%                                                 ______________________________________                                    

wherein the amount of CaO+MgO+Fe₂ O₃ is greater than 25% by weight ofthe total composition, and the total amount of Na₂ O and K₂ O is lessthan about 7 wt. %. The total iron contained in the compositions of theinvention is expressed in the form of ferric oxide (i.e., Fe₂ O₃).

The compositions defined above may, if desired, be prepared fromsubstantially pure constituents. Generally, however, they are obtainedby melting a mixture of vitrifiable raw materials, possibly additionallycontaining other metal oxides such as, for example, titanium oxide andmanganese oxide. These additional oxides are considered as impuritieswithin the scope of the invention. The total content of these impuritiesshould be maintained at less than or equal to about 3 weight percent ofthe total composition.

To permit the formation of mineral fibers from the compositions of theinvention with the use of outer centrifuging techniques, thecompositions of the invention must have a suitable, viscosity at arelatively low temperature. The viscosity of these materials depends toa great extent on the total amount of SiO₂ and Al₂ O₃ in the subjectcompositions. Within the scope of the invention, the amount of theseoxides is generally equal to or greater than about 50 weight percent ofthe total composition.

In addition, the ability to produce fibers from the compositions of theinvention is inversely proportional to the ability of the material todevelop crystals in its mass. This phenomenon, known as devitrification,is characterized by several temperatures: that at which the rate ofcrystal growth is at its maximum and that at which this rate of growthis zero, i.e., the liquidus temperature. Generally, devitrification maybe increased or decreased by adjusting the total amount of alkalineearth oxides in the composition. Within the scope of the invention, theamount of such alkaline earth oxides should be maintained at less thanabout 40 weight percent of the total composition.

Moreover, in order to ensure that the fibers formed according to theinvention are sufficiently heat resistant, it is desirable for theamount of CaO+MgO+-Fe₂ O₃ in the compositions to be greater than about25 weight percent of the composition.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A first preferred range of components for mineral fiber formed accordingto the present invention is set forth below in the following proportionsby weight:

    ______________________________________                                        SiO.sub.2             45 to 57%                                               Al.sub.2 O.sub.3      3 to 6%                                                 CaO                   20 to 30%                                               MgO                   6 to 16%                                                Fe.sub.2 O.sub.3      0.1 to 4%                                               P.sub.2 O.sub.5       1 to 7%                                                 Na.sub.2 O + K.sub.2 O                                                                              0.1 to 5%                                               Impurities            ≦3%                                              ______________________________________                                    

A second embodiment of the present invention comprises the followingcomponents in the following weight proportions:

    ______________________________________                                        SiO.sub.2             39 to 50%                                               Al.sub.2 O.sub.3      7 to 13%                                                CaO                   20 to 30%                                               MgO                   6 to 16%                                                Fe.sub.2 O.sub.3      0.1 to 4%                                               P.sub.2 O.sub.5       3 to 9%                                                 Na.sub.2 O + K.sub.2 O                                                                              0.1 to 5%                                               Impurities            ≦3%                                              ______________________________________                                    

The advantages of the mineral fiber compositions of the presentinvention are set forth in the following description, illustrated bysome non-limiting examples.

EXAMPLES

The measurements of the degree of decomposition undergone by the fibersof the present invention in the physiological medium were performed onfibers having a substantially constant diameter of approximately 10 μm.

The fibers were immersed in a solution which simulated an extracellularfluid having the following composition (expressed in g/l):

    ______________________________________                                        MgCl.sub.2.6H.sub.2 O                                                                            0.212                                                      NaCl               6.415                                                      Na.sub.2 HPO.sub.4 0.148                                                      Na.sub.2 SO.sub.4.2H.sub.2 O                                                                     0.179                                                      CaCl.sub.2.4H.sub.2 O                                                                            0.318                                                      NaHCO.sub.3        2.703                                                      (Na.sub.2 tartrate).2H.sub.2 O                                                                   0.180                                                      (Na.sub.3 citrate).5, 5H.sub.2 O                                                                 0.186                                                      Na lactate         0.175                                                      Na pyruvate        0.172                                                      Glycine            0.118                                                      ______________________________________                                    

The test conditions selected for determining the degree of decompositionof the mineral fibers in the above-described solution were as follows:200 mg of fibers were placed between two perforated discs separated by acircular ring. These two discs, each 4.3 cm in diameter, were coveredwith a polycarbonate filter. This assembly formed a measuring cellthrough which the physiological solution was circulated. The flow rateof the solution was regulated by a peristaltic pump. The flow rate ofthe solution was 40 ml per day, with the duration of the test being 20days. The cell and the flask containing the physiological solution wasmaintained at a substantially constant temperature of 37° C. Afterpassing through the cell, the physiological solution was collected inbottles to permit subsequent analysis. The amount of dissolved silicawithin the solution was thereafter measured by analysis such that theweight of dissolved silica in relation to the weight of silica initiallypresent in the fiber provided a percentage result. This percentage istherefore a good indicator of the capacity of the fiber tested todecompose in a physiological medium.

The compositions tested and the results obtained are presented in Tables1 and 2 set forth below. Table 1 sets forth several mineral fibercompositions according to the invention, as well as two prior artcompositions used as a reference (i.e., example no. 1 and no. 4). Asillustrated in Table 2, therefore, the presence of phosphorous pentoxidein compositions formed according to the present invention has thus beendemonstrated to have the effect of increasing the rate of decompositionof fibers formed from these compositions when such fibers are placed ina physiological medium.

A comparison between example nos. 1 and 3, on the one hand, and examplenos. 4 and no. 6, on the other, shows that the effect of reducing thealumina and replacing this amount by silica causes a considerableincrease in the degree of decomposition of the fibers tested.

A comparison between example nos. 2 and 3, and between example nos. 5and 6, illustrates that in examples where the degree of decomposition isconsiderable, the substitution of silica by phosphorus pentoxide resultsin a substantial increase in the degree of decomposition on the fiberstested.

The influence of phosphorus pentoxide on the degree of decomposition ofthe fibers is still quite considerable in compositions having a highalumina content, as shown by the results obtained with example nos. 4and 7.

The phosphorus containing compound is added to the vitrifiable mixtureas, for example, disodic phosphate or calcium phosphate. When the amountof phosphate introduced into the vitrifiable mixture is relativelylarge, it may sometimes be difficult to melt the mixture. It is for thisreason that the phosphorus pentoxide content of the compositions of theinvention is maintained at an amount less than or equal to about 10weight percent of the total composition.

Preferably, the compositions according to the invention comprise lessthan about 7 weight percent of alkaline oxides. Such compositions haveviscosity and devitrification properties suitable to permit theformation of mineral fibers from these compositions with the use ofouter centrifuging techniques of the type described above. In addition,as shown, the resultant fibers have a high rate of decomposition in aphysiological medium. The mineral fibers of the invention listed intable no. 1 are all resistant to temperatures of up to about 700° C. Itwas found that sample blocks of these fibers (100 kg/m³) heated into anoven during 30 minutes sag less than 10% at 700° C.

The compositions of the invention may be converted into fibers by known"outer" centrifuging devices, such as those described in U.S. Pat. Nos.2,663,051 and 4,661,134 or French Patent Publication No. 2,609,708, forexample, The disclosure of each of these references in incorporatedherein by reference.

The fibers obtained in this manner permit the formation of excellentquality fibrous products suitable for numerous applications. Thus, forexample, the fibers of the present invention may advantageously beformed into geometrically shaped panels, stiffened by a polymerizedbonding material, or into tubular products intended, e,g., for ductinsulation. Fibers produced according to the invention may also be usedto form mats sewn over cardboard or metal grills or netting in the formof pads, or even in bulk form, i.e., by filling.

                  TABLE NO.1                                                      ______________________________________                                        Compositions in weight percentages                                                  Ex.    Ex.     Ex.  Ex.  Ex.   Ex.  Ex.  Ex.                            Consti-                                                                             No.    No.     No.  No.  No.   No.  No.  No.                            tuents                                                                              1      2       3    4    5     6    7    8                              ______________________________________                                        SiO.sub.2                                                                           47.1   49.9    56.4 45.7 49.7  52.7 39.7 44.9                           Fe.sub.2 O.sub.3                                                                    12.9   12.9    12.9 2.1  2.1   2.1  2.1  10                             Al.sub.2 O.sub.3                                                                    13.8   4.5     4.5  11.5 4.5   4.5  11.5 4.5                            CaO   10.3   10.3    10.3 29.5 29.5  29.5 29.5 29.5                           Mgo   9.1    9.1     9.1  7.4  7.4   7.4  7.4  7.4                            Na.sub.2 O                                                                          2.7    2.7     2.7  1.4  1.4   1.4  1.4  1.4                            K.sub.2 O                                                                           1.2    1.2     1.2  1.3  1.3   1.3  1.3  1.3                            P.sub.2 O.sub.5                                                                     0.3    6.5     0.3  0.1  3     0.2  6    3                              Impur-                                                                              2.6    2.9     2.6  1.0  1.1   0.9  1.1  0.7                            ities                                                                         ______________________________________                                    

                  TABLE No.2                                                      ______________________________________                                        Chemical Resistance in Physiological Medium                                   Amount of dissolved SiO.sub.2 (in percent)                                    dura-                                                                         tion Ex.     Ex.    Ex.   Ex.  Ex.   Ex.  Ex.   Ex.                           of   No.     No.    No.   No.  No.   No.  No.   No.                           test 1       2      3     4    5     6    7     8                             ______________________________________                                        20   0.7     5.1    2.5   0.9  11.4  5.2  2.6   53                            days                                                                          ______________________________________                                    

While it is apparent that the invention herein disclosed is wellcalculated to fulfill the objectives stated above, it will beappreciated that numerous modifications and embodiments may be devisedby those skilled in the art. It is intended that the appended claimscover al such modifications and embodiments as fall within the truespirit and scope of the present invention.

We claim:
 1. A mineral fiber composition decomposable in a physiologicalmedium, said composition consisting essentially of:

    ______________________________________                                        SiO.sub.2         37 to 58 wt. %;                                             Al.sub.2 O.sub.3  4 to 11.5 .[.14.]. wt. %;                                   CaO               7 to 40 wt. %;                                              MgO               4 to 16 wt. %;                                              P.sub.2 O.sub.5   1 to 7 .[.10.]. wt. %;                                      Fe.sub.2 O.sub.3  0.1 to 15 wt. %;                                            Na.sub.2 O + K.sub.2 O                                                                          up to about 7 wt. %; and                                    Impurities        up to about 3 wt. %,                                        ______________________________________                                    

wherein the amount of CaO+MgO+Fe₂ O₃ is greater than 25 wt. % of thecomposition.
 2. The composition of claim 1, wherein the amount of SiO₂+Al₂ O₃ is greater than about 50 wt % of said composition.
 3. Thecomposition of claim 1 wherein the amount of CaO+MgO less than about 40wt % of said composition.
 4. A mineral fiber composition decomposable ina physiological medium, said composition consisting essentially of:

    ______________________________________                                        SiO.sub.2         45 to 57 wt. %;                                             Al.sub.2 O.sub.3  3 to 6 wt. %.                                               CaO               20 to 30 wt. %                                              MgO               6 to 16 wt. %;                                              Fe.sub.2 O.sub.3  1 to 7 wt. %;                                               P.sub.2 O.sub.5   0.1 to 4 wt. %;                                             Na.sub.2 O + K.sub.2 O                                                                          0.1 to 5 wt. %;                                             Impurities        up to about 3 wt. %                                         ______________________________________                                    

wherein the amount of CaO+MgO+Fe₂ O₃ is greater than about 25 wt % ofsaid composition.
 5. A mineral fiber composition decomposable in aphysiological medium, said composition consisting essentially of:

    ______________________________________                                        SiO.sub.2         40 to 50 wt. %;                                             Al.sub.2 O.sub.3  7 to 11.5 .[.13.]. wt. %;                                   CaO               20 to 30 wt. %;                                             MgO               6 to 16 wt. %;                                              P.sub.2 O.sub.5   3 to 7 .[.9.]. wt. %;                                       Fe.sub.2 O.sub.3  up to about 4 wt. %;                                        Na.sub.2 O + K.sub.2 O                                                                          0.1 to 5 wt. %; and                                         Impurities        up to about 3 wt. %;                                        ______________________________________                                    

wherein the amount of CaO+MgO+Fe₂ O₃ is greater than 25 wt. % of thecomposition.
 6. Mineral fibers comprising the mineral fiber compositionsset forth in any one of claims 1 to
 5. 7. An insulating materialcomprising the mineral fibers of claim
 6. .Iadd.
 8. A mineral fibercomposition decomposable in a physiological medium, said compositionconsisting essentially of:SiO₂ in an amount of about 45 to 57 wt. % Al₂O₃ in an amount of about 4 to 6 wt. % CaO in an amount of about 7 to 40wt. % MgO in an amount of about 4 to 9.1 wt. % P₂ O₅ in an amount ofabout 1 to 7 wt. % Fe₂ O₃ in an amount of about 2.1 to 15 wt. %, and Na₂O+K₂ O in an amount of about 0.1 to 5 wt. %; wherein the compositioncontains impurity elements in an amount of less than about 3 wt. % andthe amount of CaO+MgO+Fe₂ O₃ is greater than 25 wt. % of thecomposition.Iaddend.. .Iadd.
 9. A mineral fiber composition decomposablein a physiological medium, said composition consisting essentially ofabout 49.7 wt. % SiO₂, about 2.1 wt. % Fe₂ O₃, about 4.5 wt. % Al₂ O₃,about 29.5 wt. % CaO, about 7.4 wt. % MgO, about 1.4 wt. % Na₂ O, about1.3 wt. % K₂ O, about 3 wt. % P₂ O₅ and impurities in an amount of about1.1 wt. %, wherein the weight ratio of P₂ O₅ to (Al₂ O₃ and Fe₂ O₃) isabout 0.45..Iaddend.